C02S3B

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CALIBRATE A 150-TPH CRUSHER PLANT

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SECTION III. PRESENTATION

B. ELO 2: Calibrate a 150-TPH Crusher Plant

Action: Calibrate a 150-TPH crusher plant.

Conditions: At a training site, given a 150 TPH crusher plant, job specifications,TM 5-3820-256-14&P, TM 5-3820-258-14&P, a general mechanic'stool kit, a ¾” drive set with sockets, an 18” pipe wrench, a 24”adjustable wrench, a 12” ruler, a grease gun, replacement screens, acone and jaw adjustment pump, petroleum, oil, lubricants, penetratingoil, rags, appropriate maintenance forms, an equipment recordsfolder, coveralls, safety boots, goggles, gloves, double hearingprotection, a hard hat, paper, and a pencil

Standards: Calibrate a 150-TPH crusher plant IAW job specifications,TM 5-3820-256-14&P, and TM 5-3820-258-14&P, without damage toequipment or the environment and without injury to personnel.

Safety

Requirements

Hard hats must be worn at all times. Hearing protection must be worn whileequipment is running. Eye protection, gloves, and proper foot protection must beworn when operating equipment. Use three points of contact when mounting or dismounting equipment. Remove all jewelry. Use caution around moving parts.

Risk

Assessment

Level

Low

Environmental

Considerations

Avoid unnecessary stripping and damage to vegetation and waterways. Control dustconditions and limit water erosion by dressing area at the end of each day. Avoidunnecessary equipment usage and follow established procedures for cleanup of fluidleaks. Restore site and surrounding areas as close as possible to the originalecological condition.

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References

Required Number Title Date

Additional

Information

TM 5-3820-256-14&P Primary Crusher Unit, Model M3042 Jun 97

TM 5-3820-258-14&P Secondary Crusher and Screening Unit,Model M1313

Jun 97

Equipment

Required 150-TPH crusher plant

Replacement screens

Cone and jaw adjustment pump

General mechanic’s tool kit

¾” drive set with sockets

18” pipe wrench

24”adjustable wrench

12” ruler Grease gun

Materials Instructor Materials Student Materials

Required

TM 5-3820-256-14&P TM 5-3820-256-14&P

TM 5-3820-258-14&P TM 5-3820-258-14&P

Job specifications Job specifications

C02 TSP Equipment records folder

Equipment records folder Student guides

Coveralls Coveralls

Safety boots Safety boots

Goggles Goggles

Gloves Gloves

Double hearing protection Double hearing protection

Hard hats Hard hats

Pencils

Paper

InstructionalGuidance

Before presenting this lesson,a. Ensure all materials are on hand and in quantities needed.

b. Read and understand C02 TSP prior to conducting training.

c. Ensure equipment is available and on site.

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Instructional

Lead-In

Inform the students of the Enabling Learning Objective (ELO) requirements. Statethe complete action, conditions, standards, safety, risk assessment level, and

environmental considerations. Explain the importance of being able to properlycalibrate a 150-TPH crusher plant.

NOTE: Introduce the lesson topics to be discussed.

a. Setting the Discharge Opening on the Jaw Crusher

b. Adjusting the Closed Side Setting on the Cone Crusher

c. Removing and Installing the Wire Cloth

Learning Activity #1: Conduct a demonstration of setting the discharge opening on the

jaw crusher.

AC RC

Method of instruction: DM DM

Instructor-to-student ratio: 2:12 2:12

Time of instruction: 1.0 1.0

Media: Student guide Student guide

1. Setting the Discharge Opening on the Jaw Crusher

NOTE: Refer students to TM 5-3820-256-14&P.

a. The size of the crusher discharge opening governs the size of the finished material produced by

the crusher.

b. The size of the crusher discharge opening is changed by a hydraulic adjusting mechanism andshims. The opening is reduced by moving the base toggle seat forward with the hydraulic ramand shimming behind the seat.

c. Set the discharge opening.

(1) Stop the jaw crusher drive and lock out the power source when the crusher chamber iscompletely empty.

(2) Loosen the four toggle seat wedge bolts.

(3) Loosen the tension spring nuts so the shims can be added or removed.

(4) Install the hydraulic rams and pump the unit as needed.

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(5) Fabricate a wooden spacer which is the exact thickness of the desired discharge opening.This may require fabricating a lamination of plywood or hard fiber board. The spacer must beat least 24” long so it will span three jaw teeth when inserted. The spacer must be long

enough so it can be inserted into the bottom of the crusher chamber by someone standingover the top of the jaw crusher.

(6) Rotate the flywheel so the jaws close as much as possible and hold it in this position.

(7) Hold the wood spacer so it is centered in the crusher chamber and it extends below thebottom of the jaw. If increasing the jaw opening, push the movable jaw forward and removeshims before inserting wood spacer.

(8) Operate the hydraulic pump by pushing the movable jaw forward until it contacts the spacer.

(9) Install an equal number of shims on each side to hold the toggle seat in position.

(10) Tighten the four toggle seat wedge bolts.

(11) Tighten the tension spring nuts to restore the holding force on the toggle.

2. Review

Determine if students have learned the material presented by:

(1) Soliciting student questions and explanations.

(2) Asking questions and receiving answers from the students.

(3) Correcting student misunderstandings.

Learning Activity #2: Conduct a demonstration of adjusting the closed side setting (CSS) on

the cone crusher.

AC RC





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1. Adjusting the Closed Side Setting (CSS) on the Cone Crusher

NOTE: Refer students to TM 5-3820-258-14&P.

CAUTION: When connecting the electric hydraulic pump hose to the quick couplers, be certain

to clean the hose tip and check the quick coupler for dirt or other obstructions.

Ensure threads are clean and in good condition. Before starting the pump, ensure

the threaded fittings at the coupler are threaded fully and couplers are tight.

a. Check the toggle switch on the adjusting pump to ensure it is in the OFF position. Plug in thepump to an appropriate electrical outlet.

b. Connect line “B” (the bottom hose) to the adjusting jack manifold. Connect line “A” (the top hose)to the relief valve threaded into the flange of the bonnet support. Ensure the fitting snaps fully intoplace.

CAUTION: Overtightening ruins the relief valve. Use only gentle force.

c. Using a ¾” wrench, gently close the relief valve at the bottom of the small (one gallon)accumulator.

NOTE: The purpose of closing the valve at the one gallon accumulator is to retain the oil

already trapped in the accumulator. This reduces both the amount of oil needed to

repressurize the system and the amount of time required to make an adjustment.

d. Lower the shim guard.

e. Place the valve on the adjusting pump to position “B” (toward the hoses).

f. Using the ¾” wrench, slowly open the clamp cylinder manifold valve.

g. Place the toggle switch on the adjusting pump to the run position until the clamp cylinders arecompletely collapsed. Use the jog position on the switch to prevent high pressure buildup.

h. Stop the pump motor.

i. Adjust to a narrower CSS.

(1) Remove the desired shims from the lower shim stacks. Place these shims close by for use inStep 3. To determine the proper shims to remove, see Table 3-7, page 3-19, inTM 5-3820-258-14&P.

WARNING: The next step will lower the upper assembly onto the shim stack. Ensure all

personnel are clear.

(2) Once you have checked to ensure everyone is clear, move the adjusting pump valve to the“A” position (away from hoses). As this valve is opened, the upper assembly will drop into thelower shim stacks.

(3) Replace the shims that were removed from the lower shim stack into the upper shim stack.

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j. Adjust to a wider CSS.

(1) Move the control valve on the adjusting pump to the “A” position. This will loosen the upper

shim stack and allow the desired shims to be removed. To determine the proper shim toremove, see Table 3-7, page 3-19, in TM 5-820-258-14&P.

(2) After removing the desired shims, move the control valve on the adjusting pump back to the“B” position. This will raise the upper assembly enough to allow you to place the shims youhave removed from the upper stack into the lower shim stack.

WARNING: The next step will lower the upper assembly. Ensure all personnel are clear.

(3) Once all shims are replaced and everyone is clear, move the control valve on the adjustingpump back to position “A” to lower the upper assembly. As this valve is opened, the upper assembly will drop onto the shim stack.

(4) With the adjusting pump valve in the “A” position, start the pump and pressure the system to

1000 psi. Stop the pump at 1000 psi.

(5) Open the relief valve on the one gallon accumulator. If the system pressure drops, continueto pressurize with the pump until the system pressure stabilizes at 1600 psi. Stop the pump.

(6) Close the clamp cylinder relief valve.

(7) Move the control valve on the adjusting pump to the “B” position to clean the lines of pressure.

(8) Using the small pry bar, raise any one adjusting jack to a height of approximately 2”. Thisallows room in the system for any hydraulic thermal expansion or contraction without affectingthe crusher performance.

(9) Remove both hoses. Secure the pump. Raise and secure the shim guard.

2. Review





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Learning Activity #3: Conduct a demonstration of the removal and installation of wire cloth.

AC RC





1. Remove Wire Cloth

a. Remove the tail gates as needed.

b. To remove the top deck wire cloth on the signal crown deck, remove all the draw bolts and draw

plates. Lift the wire cloth out from the top.

c. To remove the wire cloth from the middle and bottom decks, remove the draw blots and drawplates. Pull all cloth out from either end of the screen.

2. Install Wire Cloth

a. Ensure all the rubber channels are in position and in good condition. Replace the channels if theyare worn to help preserve your wire cloth and screen decks.

b. Center the subscreen cloth (if used) on the screen deck. Subscreen support is only needed if youuse small mesh wire cloth with a clear square opening of about 1/8” or less, depending on your screen’s configuration.

c. Center the sizing wire cloth on the screen deck.

d. Position the draw plates and bolts. Ensure the ends of the draw plates do not catch on adjacentplates. Any overlapping causes them to pull down unevenly as the bolts are tightened. Tappingdownward on the top edge of each plate helps set the wire cloth in position.

NOTE: Too much torque on the draw bolts can damage the wire cloth draw plates or draw

bolts.

e. Tighten the draw bolts evenly. With one person working on each side of the screen basket,tighten the first pair of draw bolts directly across from each other. Continue to tighten the pairs of bolts evenly the full length of the deck.

CAUTION: The recommended torque value is 60-80 ft. lbs. Fine gauge wire mat requires lesstorque and heavy gauge wire requires more torque.

f. Repeat the tightening procedure to ensure a tight fit.

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g. The tailgate can now be put in place and tightened down. After the screen has run for a fewhours, retighten the draw bolts.

h. After installing new wire cloth, make sure it is tight and secure. Loose cloth causes unsatisfactoryscreening action and shortens the life of your wire cloth.

3. Review





Learning Activity #4: Conduct a practical exercise on calibrate a 150-TPH crusher plant.

AC RC

Method of instruction: PE1 PE1Instructor-to-student ratio: 1:4 1.4



1. Practical Exercise Instructions

a. Give detailed instructions on what is expected during each practical exercise IAW Appendix B.

b. Ensure students have required materials and references IAW Appendix B.

c. Clarify students’ questions.

d. Conduct the practical exercise IAW Appendix B.

e. Check on students’ progress and provide assistance as necessary throughout the exercise.

f. Ensure students complete the practical exercise within the allotted time.

g. Provide solutions to the practical exercise.

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2. Review





END OF PRESENTATION

Instructor

Guidance

Refer to Section IV for lesson summary.

C02S3B

Documents

Transcript of C02S3B